Submerged Arc Welding - Hobart Brothers

Metal Core Wires & Fluxesfor Submerged Arc Welding

Metal Cored Wires & Fluxes f(Composite Electrodes)Principles of OperationThe submerged arc welding process introduced in the early 1930’swas originally developed to weld longitudinal seams in large pipe.The process was developed to provide high quality weld metaldeposits by shielding the arc and the molten weld puddle from thecontaminating effects of the air through the melting of a blanket ofgranular flux.Sub Arc Advantages• High deposition and travel speed• High quality welds• Minimal arc visibility• Easily automated• Good weld bead shapes and toe lines• Excellent chemical and mechanical propertiesThe submerged arc process is widely used in heavy platefabrication. This includes the welding of:• Structural – bridge, building, and structure manufacturing• Pipe – both longitudinal seams and circumferential welds• Vessels and tanks for pressure storage use• Heavy machine components• Railcar manufacturing• Heavy construction/mining/craneWelded metal thickness ranges from a minimum of 1/16" (1.6mm)up to unlimited for single pass welds and unlimited metal thicknesson multi-pass welds using the proper joint preparation and electrodeflux combination.Benefits of Metal Core Wire vs. Solid Wire• Increased deposition rates, typically 15-30% higher (See Table 1)• Increased travel speeds• Higher wire burnoff rates• Higher quality weld deposits• A wider broader shaped penetration and fusion pattern• Greater tolerance to gaps, poor fit up, and burn through• Easily modified for special applicationsSimilar to welding with gas shielded metal core, in most submergedarc applications, the maximum productivity and quality benefits arerealized when stepping up one wire diameter from the current solidwire size.Deposition Rate % Increases with Metal Core versus Solid WireDiameterAmperage(DCEP)VoltageApprox Wire FeedSpeed IPMDeposition RateLbs/hr (Kg/hr)Metalloy Solid Metalloy SolidDepositionRate %Increase5/64" 200 29 71 63 4.9 (2.2) 4.8 (2.2) 2.08(2.0mm) 250 30 89 80 6.5 (2.9) 6.3 (2.8) 3.17300 31 115 96 8.4 (3.8) 8.1 (3.7) 3.70350 32 154 114 11.0 (4.9) 9.4 (4.3) 17.02400 33 190 137 13.7 (6.2) 11.3 (5.1) 21.24450 34 233 167 16.6 (7.5) 13.6 (6.2) 22.06500 36 284 199 20.5 (9.3) 16.0 (7.3) 28.133/32" 300 29 85 70 8.7 (3.9) 8.1 (3.7) 7.4(2.4mm) 350 30 105 80 10.7 (4.9) 9.2 (4.2) 16.3400 30 125 89 12.9 (5.9) 10.6 (4.8) 21.7450 32 150 103 15.4 (7.0) 12.6 (5.7) 22.2500 37 175 121 17.8 (8.1) 14.8 (6.7) 20.2550 37 210 139 21.1 (9.6) 16.6 (7.5) 27.1600 38 240 156 24.3 (11.0) 18.9 (8.6) 28.61/8" 450 31 76 60 12.1 (5.5) 11.8 (5.4) 2.5(3.2mm) 500 32 87 68 14.7 (6.7) 13.1 (5.9) 12.2550 32 100 75 17.3 (7.8) 14.5 (6.6) 19.3600 35 116 80 20.0 (9.1) 15.6 (7.1) 28.2650 36 135 86 23.0 (10.4) 17.6 (8.0) 30.7700 37 153 94 25.7 (11.7) 19.3 (8.7) 33.25/32" 400 30 45 37 11.2 (5.1) 10.9 (4.9) 2.7(4.0mm) 500 33 58 47 15.5 (7.0) 14.0 (6.4) 10.7600 35 69 55 19.5 (8.8) 17.2 (7.8) 13.4700 38 90 64 23.8 (10.5) 19.6 (8.9) 21.4800 40 113 75 29.8 (13.5) 23.5 (10.7) 26.8900 42 143 88 38.7 (17.6) 28.2 (12.8) 37.2Table 1

Submerged Arc WeldingClassification for Carbon Steel Electrodes and FluxesExample: F7A8-EC1 per AWS A5.17FXXX – ECXXX“F” indicates a Submergedarc welding fluxIndicates the minimum Tensile Strength(in increments of 10,000 psi)Designates the condition ofheat treatment. “A” for as-weldedand “P” for postweld heat treated“E” indicates electrode and “C”indicates composite electrode(refer to Table 2 of AWS A5.17)Indicates the temperature in °F atwhich the impact strength of the weldmetal meets or exceeds 20 ft-lbsCompositeChemical CompositionProduct Electrode Class Requirements for Weld MetalCARBON WELD METALMetalloy EM13K-S EC1 Carbon SteelMetalloy EM13K-S MOD EC1 Carbon SteelCHROMIUM-MOLYBDENUM WELD METALMetalloy B2-S ECB2 1.00 - 1.50% Chromium, .40 - .65% MolybdenumMetalloy B3-S ECB3 2.00 - 2.50% Chromium, .90 - 1.20% MolybdenumNICKEL-MOLYBDENUM WELD METALMetalloy F2-S ECF2 .40 - .80% Nickel, .40 - .65% MolybdenumMetalloy 100F3-S ECF3 .70 - 1.10% Nickel, .40 - .65% MolybdenumMANGANESE-NICKEL-MOLYBDENUM WELD METALMetalloy 92-S ECM1 .60 - 1.60% Manganese, 1.25 - 2.00% Nickel, .35% MolybdenumMetalloy 112-S ECM3 .90 - 1.80% Manganese, 1.80 - 2.60% Nickel, .20 - .70% MolybdenumMetalloy 120-S ECM4 1.30 - 2.25% Manganese, 2.00 - 2.80% Nickel, .30 - .80% MolybdenumNICKEL WELD METALMetalloy N1-S ECNi1 .75 - 1.10% NickelWELD METAL FOR WEATHERING STEELSMetalloy W-S ECW Chromium, Copper & Nickel Alloy for Weathering SteelClassification for Low-Alloy Steel Electrodes and FluxesExample: F7A8-ECNi1-Ni1 per AWS A5.23“F” indicates a Submergedarc welding fluxIndicates the minimum Tensile Strength(in increments of 10,000 psi)Designates the condition of heat treatment.“A” for as-welded and“P” for postweld heat treatedIndicates the temperature in °F atwhich the impact strength of the weldmetal meets or exceeds 20 ft-lbsFXXX - ECXX - XXIndicates the chemical compositionof the weld metal obtained with theflux and the electrodeIndicates the chemical compositionof the electrode“E” indicates electrode and “C”indicates composite electrode

(A5.17) Table for Electrode/Flux ClassificationsTRI-MARK COMPOSITE WIRES HOBART FLUX ELECTRODE/FLUX APPROVALSMetalloy EM13K-S HA-495 F7A4-EC1 CWB F49A4-EC1Metalloy EM13K-S HN-511 F7A10-EC1F7P8-EC1Metalloy EM13K-S HN-590 F7A8-EC1F7P8-EC1Metalloy EM13K-S MOD HN-511 F7A8-EC1F7P4-EC1Metalloy EM13K-S MOD HN-590 F7A8-EC1F7P4-EC1(A5.23) Table for Electrode/Flux Classifications* Contact Hobart Brothers for Charpy V-Notch ToughnessCWB F49A7-EC1CWB F43P7-EC1ABS TO AWS F7A8-EC1CWB F49A6-EC1CWB F43P6-EC1Metalloy N1-S HN-511 F7A8-ECNi1-Ni1F6P10-ECNi1-Ni1Metalloy N1-S HN-590 F7A10-ECNi1-Ni1F6P10-ECNi1-Ni1Metalloy W-S HN-590 F8A4-ECW-WMetalloy 92-S HN-511 F8A8-ECM1-M1F8P8-ECM1-M1Metalloy 92-S HN-590 F8A8-ECM1-M1F8P8-ECM1-M1Metalloy F2-S HN-511 F9A8-ECF2-F2F9P6-ECF2-F2Metalloy F2-S HN-590 F9A8-ECF2-F2F9P6-ECF2-F2Metalloy B2-S HN-511 F9P*-ECB2-B2Metalloy B3-S HN-511 F9P*-ECB3-B3Metalloy 112-S HN-511 F11A8-ECM3-M3F10P4-ECM3-M3Metalloy 100F3-S HN-511 F10A6-ECF3-F3F10P6-ECF3-F3Metalloy 100F3-S HN-590 F10A4-ECF3-F3F10P2-ECF3-F3Metalloy 120-S HN-511 F11A10-ECM4-M4 ABS F11A10-ECM4-M4 H10

Submerged Arc WeldingMetal Core Melt Off Characteristics vs Solid WireMetal coredwire hashighercurrentdensityfor higherdepositionMetal coredwire has widerprojection areawith lessturbulentweld poolMetalloy Wire Diameter Offerings• Metalloy EM13K-S AWS: EC1 5/64", 3/32", 1/8", 5/32"• Metalloy EM13K-S MOD AWS: EC1 3/32", 1/8", 5/32"• Metalloy N1-S AWS: ECNi1 3/32", 1/8", 5/32"• Metalloy W-S AWS: ECW 3/32", 1/8", 5/32"• Metalloy F2-S AWS: ECF2 5/64", 3/32", 1/8", 5/32"• Metalloy 92-S AWS: ECM1 3/32", 1/8", 5/32"• Metalloy 100F3-S AWS: ECF3 3/32", 1/8", 5/32"• Metalloy 112-S AWS: ECM3 3/32", 1/8", 5/32"• Metalloy 120-S AWS: ECM4 3/32", 1/8", 5/32"• Metalloy B2-S AWS: ECB2 5/64", 3/32", 1/8", 5/32"• Metalloy B3-S AWS: ECB3 5/64", 3/32", 1/8", 5/32"Standard Packaging: 60lb (27.2 Kg) coils and 600lb (272 Kg) drums• Contact Hobart Brothers for additional available diameters.Diameter Conversions:5/64"= 2.0mm 3/32"= 2.4mm 1/8"= 3.2mm 5/32"= 4.0mmHobart Fluxes:Neutral and active agglomerated fluxes are now available to providea single source for both flux and wire. These fluxes are high inperformance, quality, and generate weld deposits with excellentmechanical properties. Flux particle size is uniform through controlledmesh screening. The flux is free flowing with consistent weld puddledegassing due to the minimum number of fines.Electrode/Flux – Cross ReferenceSubmerged Arc WireTriMarkMetalloyEM13K-SCompositeWire AWS ClassCompositeWire AWS Class Lincoln ESABEC1 EM13K L-50L-61SPOOLARC 29SSPOOLARC 81Metalloy N1-S ECNi1 ECNi1 LA-75 SPOOLARC 75Metalloy F2-S ECF2 EF2 LA-82Metalloy W-S ECWMetalloy 92-S ECM1Metalloy 100F3-S ECF3 EF3 LA-84Metalloy 112-S ECM3Metalloy 120-S ECM4Metalloy B2-S ECB2 LAC-B2 SPOOL ARCU515Metalloy B3-S ECB3 EB3 LA-93Available flux types:Hobart Brand Packaging Part Number• HN-590 N=Neutral 55lb (25kg) bag S669610-055• HN-511 N=Neutral 55lb (25kg) bag S669310-055• HA-495 A=Active 55lb (25kg) bag S669410-055See product data sheets for AWS deposited weldmetal class, weld metal chemistry, and mechanicalproperties with specific flux/wire combinations.Please remember there is no AWS class for flux!! AWSclassifies flux/wire combinations with a deposited weldmetal classification system under A5.17 for carbon (mild)steel filler metals and A5.23 for low alloy filler metals.Examples: A5.17:F7A6-EC1, A5.23:F7A10-ECNi1-Ni1Submerged Arc FluxHOBART LINCOLN ESABHN-590 860 OK Flux 429, OK Flux 10.71HN-511 880M, 8500 OK Flux 10.62HA-495 761, 780 OK Flux 231, OK Flux 350

History ofAfter 90 years in the business,Hobart Brothers is Welding. AndWelding is Hobart Brothers.Much has changed in industry since 1920;Hobart Brothers was there every step ofthe way. You might even say the companydid more than simply keep up with newtechnologies and processes.It helped forge them.Hobart has become a world leader in thefield. Today you can find the broadestselection of filler metals in the United States.&are wellknown brands of Hobart Brothers.Training and expertise are key toHobart Brothers.Such a respectable past can only be built byknowledgeable people. That’s why, whetheryou have a question on technique, materialsor applications, you know who to call.1-800-532-2618The company who started that firstspark over 90 years ago.Hobart Brothers has served major metalfabrication markets as a top-qualitymanufacturer of stick, flux-cored and metalcoredwires for over 25 years. Throughoutthat time, we’ve consistently focused ourHobart DistributorsTo locate your nearest Hobart distributor call 1-937-332-4000 or 1-937-332-5188or visit our Web site www.hobartbrothers.comHeadquartersHobart Brothers Company 101 Trade Square East Troy, OH 45373 Phone: 937-332-4000 Fax: 937-332-5700efforts on welding research and productdevelopment and, as a result, now offer oneof the most complete product lines in theindustry today. Recognized worldwide asthe “specialists in flux-cored and metal-coredwires,” Hobart Brothers features over 52different products for welding carbon andlow alloy steels, in addition to specialformulations for applications in the shipbuilding,infrastructure construction, offshoreoil, and heavy equipment industries.www.MillerWelds.com800-4-A-MILLER(800-426-4553)International HeadquartersPhone: 937-332-5188FAX: 937-332-5064Regional Office - CanadaCanadian Welding Products GroupPhone: (519)-537-6291Fax: (519)-421-0480Regional Office - Middle EastPhone: +971-4299-6621FAX: +971-4299-6681E-mail: itwme@emirates.net.aeRegional Office - IndiaPhone: +91-222520-7388FAX: +91-222520-7389E-mail: itwweldi@satyam.net.inRegional Office - AsiaPhone: 65-6552-1223FAX: 65-6552-1929E-mail: vmarta@millerwelds.comBeijing Miller ElectricPhone: +86-10-8739-7900FAX: +86-10-8739-7600E-mail: lisa.li@millerchina.comRegional Office - BrazilPhone: +55-11-5514-3366FAX: +55-11-5891-7679E-mail: itwsoldagem@osite.com.brWeb site: www.itwsoldagem.com.brRegional Office - FrancePhone: +33-1-6004-1166FAX : +33-1-6004-8860E-mail: miller@itw-welding.frWeb site: www.miller-france.comRegional Office - ItalyPhone: +39-02-9829-0218FAX : +39-02-9828-1552E-mail: millerit@itw-welding.itRegional Office - NetherlandsPhone: +311-866-41456FAX : +311-866-49020E-mail: info@itw-welding.nlWeb site: www.itw-welding.comRegional Office - MexicoPhone: +52-55-5366-7370FAX : +52-55-5366-7376E-mail: jflore@millerwelds.comWeb site: www.itwweldingmexico.comWelding Industries of AustraliaPhone: +61-1300-300-884FAX: +61-8-827-66327E-mail: intc@welding.com.auWeb site: www.welding.com.auWeldwell New ZealandPhone: +64-6-834-1600FAX: +64-6-835-4568E-mail: admin@weldwell.co.nzWeb site: www.weldwell.co.nzRegional Office - Northern EuropePhone: 46-031-726-4600FAX: 46-031-726-4700E-mail: per.gelang@itw-welding.seWeb site: www.elga.seRegional Office - RussiaPhone: +7-812-961-5481E-mail: infosvarka@itw-welding.ruWeb site: www.itw-welding.ruRegional Office - SpainPhone: 34-963935398FAX: 34-963629516E-mail: vcubero@itw-welding.esRegional Office - AfricaPhone: +44-7770562799FAX: +44-1204-473039E-mail: Andy.Foster@itw-welding.co.ukWeb site: www.itw-welding.co.ukRegional Office for:Colombia, Venezuela,Trinidad & Tobago, PanamaPhone: 920-968-7508FAX: 920-735-4125E-mail: mferna@millerwelds.comEcuador, Peru, Bolivia, Chile,Argentina, Uruguay, ParaguayPhone: 920-968-7508E-mail: mferna@millerwelds.comGuatemala, El Salvador, Honduras,Nicaragua, Costa Rica, BelizePhone: 525553667370FAX: 525553667388E-mail: ventas@itwwelding.com.mxBahamas, Barbados, DominicanRepublic, Jamaica, Puerto Rico,Virgin IslandsPhone: 937-332-5188FAX: 937-332-5064E-mail: quafile@hobartbrothers.comManufacturers:Tien Tai Electrode Co., LTDPhone: 886-6-2663721Fax: 886-6-2664301Web site: www.tientai.comTien Tai Electrode (Kun Shan) Co.Phone: 86-51257446669FAX: 86-51257448416E-mail fuhu.chen@tientai.com.cnWeb site: www.tientai.comElga ABPhone: +46-31-726-46 00FAX: +46-31-726-47-00Web site: www.elgawelding.comwww.smithequipment.com | 800-843-7912www.bernardwelds.com | 800-946-2281www.weldcraft.com | 800-752-7620www.tempil.com | 800-757-8301www.jetline.com | 949-951-1515www.magnaflux.com | 847-657-5300www.welding.org 800-332-9448937-332-5000www.tregaskiss.com 877-737-3111519-737-3000®REV. 2/10